KMK have the capability and capacity to produce a custom-built compensator profile to suit your specific needs.
However the vast majority of applications can be met from the five standard compensator profiles detailed below:
Compensator profile design 1 is suitable only for applications operating under vacuum. For any given distance between the flanges, the depth of the compensator profile increases as flange separation reduces due to expansion. To prevent the compensator protruding into the gas stream, or fouling any flow plate, the flange depth must be increased as a function of the original gap and the amount of expansion. The minimum recommended flange depth for Compensator Profile 1 is 100mm. Installation of Profile 1 is relatively simple, as access is required only on the outside and loose nuts and bolts can be used for fastening.
Compensator profile design 2 is intended only for applications operating under pressure. There is a similar relationship between profile height, flange gap and expansion as with profile 1. Since there is often little to foul the outside of the compensator, protrusion does not normally create problems.
Because of the design of profile 2, loose bolts are not recommended, as access from inside is sometimes difficult. It is recommended that studs or welded bolts be used for fastening. This method also allows the compensator to be hung in position prior to fixing. We do not recommend the use of nuts welded to the flanges since difficulties in bolt location can be experienced. The recommended minimum flange depth for profile 2 is 50mm.
Compensator profile design 3 is used for pressure applications where it is undesirable to have any part of the compensator protruding beyond the flanges. Fitting can be done from the outside using loose bolts.
The recommended minimum flange depth for Profile 3 is normally 100mm, but smaller flanges may be acceptable under certain circumstances.
Compensator profile design 7 is suitable for both positive and negative pressure being the most versitile of all the profiles. It is extremely simple to install using loose bolts.
The recomended minimum flange depth is 100mm for vacuum and 50mm for pressure applications.
The recommended minimum flange with for bolting the compensator is 40mm for both vacuum and pressure applications.
Compensator profile design 8 is normally used where there are relatively small flange and little movement; both axially and laterally. Profile 8 can be used for both positive and negative pressure. The recomended minimum flange depth is 75mm.
Standard mild steel angles or channels should be used and for adequate rigidity and maximum flange thickness of 6mm is
The clamping bars used to secure the compensator should be between 6 and 10mm thick. Both pitches should be between 100 and 150mm for M12 minimum diameter bolts.
The optimum distance between flanges can be fixed conveniently at between 100 and 150mm. Depending on the movement involved, the minimum gap to be considered is 50mm, with a maximum of 800mm. It is not expected that large gaps will be designed in original equipment, but they can be found where a fabric compensator is replacing a metal bellows. Even here, it is recommended that consideration should be given to reducing the gap to the suggested dimensions.
These should always be included in the flange design. Their main function is to protect the compensator from abrasive particals in the gas stream and to help prevent the deposition of solid matter in the bottom of the compensator. Build-up of such deposits may restrict the movement of the compensator or damage the compensator itself.
Flow plates are also useful in maintaining laminar gas flow and preventing turbulence at the compensator which, if excessive, could eventually lead to its mechanical failure. They are strongly recommended where the flow rate exceeds 5 m/s.